Socket Adapter for Test Cables Using Mechanical Pin Locking
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for creating a socket adapter to connect test devices to motor vehicle control units are complex, error-prone, and costly, particularly due to the need for soldering individual contact pins to circuit boards.
Innovation Solution
A socket adapter using a connector strip with a contact holding plate and locking plate, allowing for a cost-effective and reliable connection of contact pins to a socket without soldering, utilizing through-openings for plug-in shoes and spacers for insulation and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering is used to connect contact pins to circuit board, then reliable electrical connection is achieved, but manufacturing complexity and error risk increase significantly
Solution Approach 1:
The patent replaces the soldering process (thermal/chemical joining method) with a mechanical pressing system. Contact pins are inserted through through-openings in the contact holding plate and secured by locking plates that apply mechanical pressure to create reliable electrical connections without soldering, thereby reducing manufacturing complexity while maintaining connection reliability.
Solution Approach 2:
The contact holding plate serves as an intermediary component between the contact pins and the locking plate. It provides through-openings that guide and position the contact pins, and its structure distributes the locking force evenly across multiple contact pins, enabling reliable mechanical connections without direct complex assembly between locking mechanisms and individual contacts.
2Productivity
If prefabricated industrially manufactured plug units are purchased, then production time is reduced, but production costs increase significantly
Solution Approach 1:
The socket adapter is segmented into separate, independently manufacturable components: connector strip, contact holding plate, and locking plate. These modular components can be manufactured using standard PCB and metal stamping processes, then assembled quickly through simple insertion and locking operations, achieving both cost-effectiveness and high production speed without requiring expensive prefabricated plug units.
Solution Approach 2:
The contact holding plate serves multiple functions simultaneously: it provides structural support for contact pins, offers through-openings for insertion and positioning, provides electrical insulation between adjacent contacts, and works with the locking plate to secure connections. This multi-functionality reduces the number of separate components needed, lowering overall manufacturing cost while maintaining assembly speed.
3Strength
If individual contact pins are soldered to circuit board, then secure connection is achieved, but manufacturing time and error probability increase
Solution Approach 1:
Contact pins are pre-inserted through the through-openings of the contact holding plate before the locking plate is applied. This preliminary positioning ensures correct alignment and insertion depth, allowing the subsequent locking operation to quickly secure all contacts simultaneously without requiring time-consuming individual soldering operations, thereby maintaining connection strength while reducing manufacturing time.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a test cable as well as a socket adapter for a test cable wherein the socket adapter has a plug strip with contact pins arranged at a distance from each other on a base body and having a socket contact section and a printed circuit board contact section and has a contact holding plate connected with the base body with individual through holes delimiting the printed circuit board contact sections from each other, each of which are designed for the fixed receiving of a lug arranged on a lead end.